Patent Application
20140178205
The subject matter disclosed herein relates to wind turbine rotor blades and, more specifically, to joints for connecting blade segments of wind turbine rotor blades
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known foil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
The size, shape, and weight of rotor blades are factors that contribute to energy efficiencies of wind turbines. An increase in rotor blade size increases the energy production of a wind turbine, while a decrease in weight also furthers the efficiency of a wind turbine. Furthermore, as rotor blade sizes grow, extra attention needs to be given to the structural integrity of the rotor blades. Presently, large commercial wind turbines in existence and in development are capable of generating from about 1.5 to about 12.5 megawatts of power. These larger wind turbines may have rotor blade assemblies larger than 90 meters in diameter. Additionally, advances in rotor blade shape encourage the manufacture of a forward swept-shaped rotor blade having a general arcuate contour from the root to the tip of the blade, providing improved aerodynamics. Accordingly, efforts to increase rotor blade size, decrease rotor blade weight, and increase rotor blade strength, while also improving rotor blade aerodynamics, aid in the continuing growth of wind turbine technology and the adoption of wind energy as an alternative energy source.
As the size of wind turbines increases, particularly the size of the rotor blades, so do the respective costs of manufacturing, transporting, and assembly of the wind turbines. The economic benefits of increased wind turbine sizes must be weighed against these factors. For example, the costs of pre-forming, transporting, and erecting a wind turbine having rotor blades in the range of 90 meters may significantly impact the economic advantage of a larger wind turbine.
One known strategy for reducing the costs of pre-forming, transporting, and erecting wind turbines having rotor blades of increasing sizes is to manufacture the rotor blades in blade segments. The blade segments may be assembled to form the rotor blade after, for example, the individual blade segments are transported to an erection location. However, known devices and apparatus for connecting the blade segments together may have a variety of disadvantages. For example, the use of standardized connection pieces (e.g., uniformly sized bolts or the like) may utilize unnecessary material and compromise the structure of the rotor blade by removing composite material to accommodate oversized bolts. Additionally, the application of, for example, a bonding material to known devices may be difficult. For example, known devices may cause difficulties in observing and inspecting the injection or infusion of bonding material between adjacent blade segments. Further, known connection devices generally do not allow for disassembly after the rotor blade has been formed, thus preventing the removal of individual blade segments for inspection, maintenance, replacement, or upgrading.
Accordingly, alternative joints for connecting blades segments of wind turbine rotor blades would be welcome in the art.
In one embodiment, a joint is disclosed for connecting a first blade segment to a second blade segment of a wind turbine rotor blade. The joint includes a first bolt comprising a first proximal end connected to the first blade segment and a first distal end connected to the second blade segment. The joint also includes a second bolt comprising a second proximal end connected to the first blade segment and a second distal end connected to the second blade segment. The joint also includes a third bolt comprising a third proximal end connected to the first blade segment and a third distal end connected to the third blade segment. The first bolt, the second bolt and the third bolt differ in size, and a first distance between the first bolt and the second bolt is different than a second distance between the second bolt and the third bolt.
In another embodiment, a joint is disclosed for connecting a first blade segment to a second blade segment of a wind turbine rotor blade. The joint includes a center area between a leading edge and a trailing edge, and a plurality of bolts connecting the first blade segment to the second blade segment. At least two of the plurality of bolts change in size towards the center area, and the plurality of bolts are separated from each other by different distances towards the center area.
In yet another embodiment, a method is disclosed for connecting a first blade segment to a second blade segment of a wind turbine rotor blade at a joint. The method includes connecting proximal ends of a plurality of bolts to a first blade segment, and connecting distal ends of the plurality of bolts to a second blade segment. The first blade segment and the second blade segment form a center area between a leading edge and a trailing edge at the joint, a size parameter of the plurality of bolts changes towards the center area, and the plurality of bolts are separated from each other by different distances towards the center area.
These and additional features provided by the embodiments discussed herein will be more fully understood in view of the following detailed description, in conjunction with the drawings.
The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the inventions defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
Referring to
In general, the rotor blade 16, and thus each blade segment 20, may include a pressure side 32 and a suction side 34 extending between a leading edge 36 and a trailing edge 38. Additionally, the rotor blade 16 may have a span 42 and a chord 44. The chord 44 may change throughout the span 42 of the rotor blade 16. Thus, a local chord 46 may be defined at any span-wise location on the rotor blade 16 or any blade segment 20 thereof.
The rotor blade 16 may, in exemplary embodiments, be curved. Curving of the rotor blade 16 may entail bending the rotor blade 16 in a generally flapwise direction and/or in a generally edgewise direction. The flapwise direction is a direction substantially perpendicular to a transverse axis through a cross-section of the widest side of the rotor blade 16. Alternatively, the flapwise direction may be construed as the direction (or the opposite direction) in which the aerodynamic lift acts on the rotor blade 16. The edgewise direction is perpendicular to the flapwise direction. Flapwise curvature of the rotor blade 16 is also known as pre-bend, while edgewise curvature is also known as sweep. Thus, a curved rotor blade 16 may be pre-bent and/or swept. Curving may enable the rotor blade 16 to better withstand flapwise and edgewise loads during operation of the wind turbine 10, and may further provide clearance for the rotor blade 16 from the tower 12 during operation of the wind turbine 10.
Still referring to
Joints 100 according to the present disclosure may allow for more efficient and on-site connection of adjacent blade segments 20. For example, a joint 100 may allow for access to and connection of blade segments 20 from external to the joint 100 and blade segments 20. Additionally, joint 100 can utilize mechanical fasteners for connection to at least one of the adjacent blade segments 20, thus allowing for easier connection and inspection thereof. Such joints 100 may further allow for disassembly of the various adjacent blade segments 20 after the rotor blade 16 has been formed, thus allowing for the removal of individual blade segments 20 for inspection, maintenance, replacement and/or upgrading.
As best illustrated in
The bolts 120 utilized in the joint 100 comprise non-uniform sizes across the joint. The “size” of the bolt can refer to any dimensional measurement (i.e., size parameter) such as its length, cross sectional area, weight or other dimension that would have an effect on its support capabilities in the joint. Furthermore, the size of the bolt 120 utilized in the joint 100 can depend on its location within the joint 100 with respect to the leading edge 36, center area 37 and trailing edge 38. Particularly, larger and stronger bolts 120 may be disposed more proximate the center area 37 since the center area 37 may sustain relatively larger forces during the operation of the rotor blade 16. Likewise, smaller bolts 120 may be disposed more proximate the ledge edge 37 and trailing edge 38 since those locations sustain relatively smaller forces during operation of the rotor blade 16.
For example, referring to
The length of each particular bolt 120 can be selected based on its location within the joint 100. For example, if the first bolt 121 is more proximate the center area 37 than the second bolt 122, than the first bolt 121 may be longer than the second bolt 122. Likewise, if the third bolt 123 is even farther than the center area 37 than the second bolt 122 (such that it is closer to the leading edge 36 or trailing edge 38), than the third bolt 123 may be shorter than the second bolt 122. The tapering lengths of the first bolt 121, second bolt 122 and third bolt 123 can provide the necessary amount of strength for that specific location on the joint 100 without using excess material where not required (e.g., at the leading edge 36 and/or trailing edge 38).
Similarly, the first bolt 121, second bolt 122 and third bolt 123 can comprise different cross sectional areas (e.g., thicknesses) such that at least one of the three bolts 121, 122 and 123 has a larger cross sectional area than the other two. In some embodiments, all three bolts 121, 122 and 123 may have different cross sectional areas. In other embodiments, two of the bolts (e.g., the first bolt 121 and the second bolt 122) may each have a first cross sectional area and the other bolt (e.g., the third bolt 123) may have a second cross sectional area different than the first cross sectional area.
The cross sectional area of each particular bolt 120 can be selected based on its location within the joint 100. For example, if the first bolt 121 is more proximate the center area 37 than the second bolt 122, than the first bolt 121 may have a larger cross sectional area than the second bolt 122. Likewise, if the third bolt 123 is even farther than the center area 37 than the second bolt 122 (such that it is closer to the leading edge 36 or trailing edge 38), than the third bolt 123 may have a smaller cross sectional area than the second bolt 122. The tapering sizes of the cross sectional areas of the first bolt 121, second bolt 122 and third bolt 123 can provide the necessary amount of strength for that specific location on the joint 100 without using excess material where not required (e.g., at the leading edge 36 and/or trailing edge 38).
Still referring to
In some embodiments, the distances separating the bolts 120 may be shorter towards the center area 37 of the joint 100. Specifically, as best illustrated n
Referring now to
Referring now to
Referring now to
The threaded inserts 140 can also vary in size and distance to correspond with their respective bolts 120. For example, threaded inserts 140 more proximate the center area 37 may be longer to accommodate longer bolts 120 while threaded inserts 140 more proximate the leading edge 36 or trailing edge 38 may be shorter to accommodate shorter bolts 120 without waiting unnecessary material. Likewise, threaded inserts 140 more proximate the center area 37 may have larger cross sectional areas to accommodate bolts 120 with larger cross sectional areas and threaded inserts 140 more proximate the leading edge 36 or trailing edge 38 may have smaller cross sectional areas to accommodate bolts 120 with smaller cross section areas. In even some embodiments, the threaded inserts 140 may be separated from each other by shorter distances towards the center area 37 to mirror bolts 120 that are similarly separated from each other by short distances towards the center area 37. While exemplary variations of threaded inserts 140 have been presented herein, it should be appreciated that additional or alternative embodiments may also be realized to receive the bolts 120 connected between the first blade segment 101 and the second blade segment 102.
Moreover, in some embodiments, such as those illustrated in
By having a joint 100 with bolts 120 alternating directions, the bolts may potentially be disposed closer to one another. Specifically, when one of the connection types is wider (or otherwise takes up more space) than the second connection type, an alternating orientation can allow for closer spacing by alternating the sides at which the wider connecting type is disposed. The alternating directions of bolts 120 can thereby provide greater support and/or greater distribution of the support use to connection the joint 100.
The joint 100 itself may comprise any material and construction that accompanies a rotor blade 16 for a wind turbine 10. For example, in some embodiments the joint 100 can comprise one or more composite materials. In such embodiments, the bolts 120, bore holes 110, threaded inserts 140 and/or any other connection accessory may be manufactured into the composite material during manufacturing, or may be inserted into the composite material post manufacturing during a retrofit operation. In some embodiments, the joint area 100 can comprise a composite material disposed between two sections of spar caps. In other embodiments, the joint 100 may comprise any other material and construction that allows for multiple blade segments 20 for form the rotor blade 16. The composite material (or other material comprising the joint 100) can also have increasing thickness towards the center area 37. For example, as illustrated in
In some embodiments, a method for joining multiple blade segments 20 may be achieved using the joints 100 disclosed herein. For example, the method can comprise connecting proximal ends of a plurality of bolts 120 to a first blade segment 101 and connecting distal ends of the plurality of bolts 120 to a second blade segment 102. The connections can be made in any order such as connecting all the bolts 120 to the first blade segment 101 prior to connecting the bolts 120 to the second blades segment, connecting all the bolts 120 to the second blade segment 102 prior to connecting the bolts 120 to the first blade segment 101, or alternating connecting the bolts 120 between the first blade segment 101 and the second blade segment 102. Moreover, the connection may be achieved through any suitable means such as through barrel nuts, threaded inserts, or any other operable structure such as those discussed above.
The first blade segment 101 and the second blade segment 102 form a center area 37 between a leading edge 36 and a trailing edge 38 at the joint 100. As also discussed above, a size parameter of the plurality of bolts 120 changes towards the center area 37, and the plurality of bolts 120 are separated from each other by different distances towards the center area 37. The size parameter can include the length, cross sectional area, weight or other dimension that would have an effect on the support capabilities of the plurality of bolts 120 in the joint. In some embodiments, the size parameter increases towards the center area 37 so that larger, strong bolts 120 are disposed where the joint 100 may experience greater stress. Moreover, in some embodiments, the plurality of bolts 120 are separated from each other by shorter distances towards the center area 37 so that bolts 120 are closer together where the joint 100 may experience greater stress.
It should now be appreciated that that joints 100 can comprise a plurality of bolts that vary in size, spacing and/or direction based on their respective location about the joint. By varying the size, spacing and/or direction, the bolts can be tailored to provide the requisite amount of support specific to that location without using unnecessary material and manufacturing costs that would occur using uniform bolts and/or uniform spacing. The joints can thereby provide rotor blades with increased sizes while also increasing the securing efficiency of the bolts utilized therein.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
